Machine for making multiply building board



April 28, 1931. H, CUMFER 1,802,878

MACHINE FOR MAKING MULTIPLY BUILDING BOARD Filed June 24, 1929 5Sheets-Sheet 1 Jh-Je 72 1'01; I

Harry J1. Can/(fer;

April 28, 1931. H. A. CUMFER 7 MACHINE FOR MAKING MULTIPLY BUILDINGBOARD Filed June 24'. 1929 5 Sheets-Sheet 2 April 28, 1931.

MACHINE H. A. CUMFER 1,802,878

FOR IAKING MULTIPLY BUILDING BOARD Filed June 24. 1929 s Sheets-Sheet sQ fiii/enfor M Harv/1 (inn/Er,

April 1931- H. A. CUMFER MACHINE FOR KING MULTIPLY BUILDING BOARD FiledJune 24, 1929 S'Sheets-Sheet 4 Apnl 28, 1931. H. A. CUMFER 1,802,878

MACHINE FOR MAKING MULTIPLY BUILDING BOARD Filed June 24 1929 5Sheets-Sheet 5 lllHH F I 000 0 o o o oi;

6g 1 5 I A\ 51 6 46 .[72 249-22 tor-r liar/" 12 (inn/"e77 jig PatentedApr. 1931 UNITED STATES PATENT OFFICE HARRY A. 0mm 0]? GHIGAGO,ILLINOIS, ASSIGITOR 0F ONE-EAL? '1!) user, or can, mmcrrcu'r ncnnm iron.ammo murmur 311mm. roam) Application filed-June 24, 1929. Serial No.378,090.

The present invention relates to improvements in a machine for themanufacture of building board, plaster board-or the like,

and has for one of its principal objects the provision of a device towhich a plurality of separate sheets of material are fed, operated uponcontinuously and united, the resultant product issuing from the machinein a finished condition ready to be packed and marketed.

The device of the present invention has been designed particularly forthe manufacture of a building board suitable for use as a plasterbasecomprising essentially a flat base sheet, one surface of which is coatedwith an adhesive (which is also preferably a waterproofing material,such as asphalt), while a second sheet is provided with corrugations andis united to the flat base sheet through the medium of the adhesive toprowasted, and two, the upper surface of the cut-out being devoid ofadhesive presents a surface having an atlinity for plaster. Thus, whenthe plaster passes through the aperture it will key with the corrugatedsheet as well as with the base sheet through the medium of the cut-outunited therewith.

Among the important objects of this in the second'luneorrugated sheet;means for completely severing the scored portions and positivelyattaching the cut-outs thus produced with the uncorrugated sheet, and

means for the two sheets in positive contact until the adhesive has setsufficiently to permit the composite structure to be cut into board of asize convenient for marketing.

In one preferred embodiment of. the invention, the flat base sheetpreferably com prises a laminated multi-ply structure made up by unitinga pluralityof separate plies, although it is to be understood that themachine is designed to produce a board structure in which either or boththe base sheet or the corrugated sheet may comprise one or a number oflaminated plies. p

In its preferred operation, the machine of the present invention unitesthe cut-outs to the base sheet immediately opposite to the aperturesthus formed in the corrugated I sheet.

Another important object of the invention is to provide means formanufacturing a fibrous structure which may be used in place of theusual laths, the plaster being applied to the corrugated surfacesqueezing into the apertures provided therein, thereby keying theplaster to the board. By means of the present invention the board may bemanuactured economically, and due to its waterprolofing qualitiessurpasses the conventional lat 7 Other and further important objects ofthe invention as well as advantages will be apparent from theaccompanying drawings and the following description.

In the drawings, Figs. 1 and 1a taken together illustrate in sideelevation the machine of the present invention; i

Fig. 2 is a. top plan view of the device shown in Fig. 1, with partsbroken away for clearness. Fig. 3 is a fragmentary sectional elevationalview, part1 diagrammatic, illustrating particularly t e essentialinstrumentalities of the. machine. 1

Fig. 4 is a fra entary sectional View of the product prodii ced by the',machine, in contact with the corrugatmg bar chain.

Fig. 5 is a fragmentary top plan view of a. portion of the device shownin Fig. 10:.

Fig. 6 is a transverse sectional view taken on line 66 of Fi looking inthe direction indicated by t e arrows.

Referring more parti ularly to the drawings 1 indicates enerally theframe of the machine, mountef on the front end of which are a pluralityof horizontally disposed rollers 2 suitably positioned one above theother. The rollers 2 are adapted to guide a plurality of strips of fiberboard 3 to the machine from conventional supply rolls (not shown). Atank or vat 44 positioned adjacent the lower front end portion of theframe 1 is adapted to contain an adhesive material (which is alsopreferabl a water roofin material), such as aspha t or the 'ke. pump 5is positioned within the vat 4 adapted to transfer the adhesive materialfrom the tank to the surfacesof the sheets 3, through anupstanding'conduit 6 rovided with a series of transversely extend dpipes 7 dis osed between the strips 3. The strips are t en passedthrough a pair of co acting pressure rolls 8 and 9, said rolls beingmounted in bear blocks 10 and 11, respectively. The bearin block 11, maybe fixed relative to a pair 0 guides or trunnions 12 com rising aportion of the frame 1,-Whereas the lock 10 ma be slidabl positioned between said gui es. The block 10 may be adjusted vertically by means of ahand wheel 13 mounted at the upper portion of the trunnions. The wheel13 is rigidly connected to a shaft 14 which has mounted thereon adjacentits ends bevel gears 15 (Fi 2) which in turn mesh with cooperating velgears 16 mounted upon adjustin screws 17 In passing through the rolls 8and 9 the separate strips 3 are adhesively united, forming a laminatedboard 18. After passin through the pressure rolls 8 and 9, an ad 'tionaluantity of adhesive 'material'is applied to t e upper surface of theboard 18. The board 18 then asses through a set of doctor rolls 19wherein the adhes ve materialis uniformly spread over the surfaces andthen through a set of scrapers 20 where excess adhesive material isreinoved, the same dropping back into the vat A roller 2', similar torollers 2, is mounted above rollers 2 upon the frame 1. A strip of fiberboard 3 is ada ted to be guided by the roller 2' to an and 'ary guideroller 21, from which the strip 3 is directed to a corru atin' unit 22,comprising 3 having longitudina ribs 24 on its sur ace. 'An endlesschain of pressure bars 25 is a'daptedto pass over the cylinder 23, theindividual bars- 26 being ada ted to so register with the'channelsformed tween the ribs 24. The cylinder 23' in contact with the bars 26meshes with a co-acting cylinder 27, provided with a series of alternatelarge and small ribs 28 and 29. U n rotation 5 of the cylinders thepoint of contact of the two cylinders alternately presents a rib 24juxtaposed to a rib 28, and a bar 26 to a bead 29, thus producin acorrugated sheet, as shown best at 30 in i re 4. The cylinder 23 isadjustable with respect to the cylinder 27, the bearing blocks 31 beingslidable within the guides 32, the latter being actuated by means of thehand wheel 33, (Fig. 1), shaft34, and accompanying gears 35 and 36, theadjusting mechanism being similar to that associated with the pressurerolls 8 and 9.

After leaving the corrugating unit 22, the corrugated strip 30 inregistration with the bar chain 25 to prevent collapse of, the

corrugations, passes to a scoring -unit 37,

which comprises a cylinder 38, having longitudinal ribs 39' formed uponits surface and a cylinder 40, having a plurality of appropriatelyspaced scoring dies 41 dis posed upon its surface. The scoring dies 41comprise body members 42 (Fig. 3) vided with central apertures 43 defineby knife edges. Adapted to be ositioned in the apertures 43 areresilient p ugs'44 which may be constructed of rubber, composition, ormay if desired take the form 0 spring impelled plungers. In operation,the dies 41 are adapted to score, but not completely sever, the crestsof the corrugated strip 30; hence, the provision of the resilient plugs44, which prevent the knife edges from severing the fiber sheet.

In passing from the corrugating unit 22 the lower surface of thecorrugated strip g 30 contacts and slides upon an inclined platform 45,positioned immediatel%below the pa th of the bar chain 25. ence, thecorrugated element is held in position by the chain at the top and the patform 45 at the bottom, thereby eliminating the possibility of"stretching said strip. After passing through the scoring unit 37, the

int of contact of the two cylinders 38 and 40 alternately presents a rib39 on the cylinder 38 and a series of scorin members 41, then a bar 26in contact wit the two 0 lindrical surfaces. As shown best in i i 3, therectangular crests 46 are partia 1y cut from the bottom upwardly b thescoring members 41. Although, as s own in the specific embodiment of,thedevice, circular tabs are scored, I do not wish to be any suitablesource of power (not shown),

such as an electric motor, power engine, or

limited to an articular configured scoring 'a cylinder 23 di the per thelike. A bevel gear 49 is suitably keyed to the shaft 48 and is adaptedto mesh with a bevel gear 50 rigidly connected to a spur gear (notshown) which in turn is operativel associated with the lower pressureroll 9. last mentioned spur gear is adapted to mesh with a spur gear 51operatively connected to the upper pressure roll 8. Hence, the twopressure rolls 8 and 9 turn in synchronism with'each other.

Another bevel gear 52, also mounted upon the drive shaft 48 may meshwith a bevel gear 53, which may be rigidly connected to a spur gear 54,which inturn may drive an idler gear 55. The idler 55 may mesh with aspur gear 56 operatively connected to the scoring cylinder 40. The gear56 may mesh with another/gear 57 connected to the upper cylinder 38 ofthe scoring unit. An'i ler gear 58 may be interposed between! the gear56 and a gear 59, which latter gear is operatively connected tothe lowercylinder 27 ot the corrugating unit. The gear 59 may mesh with a gear 60operatively connected to the up er cylinder 23 of the corrugating unit.ence, by means of the above described tgear train, the corrugating unitand crating unit operate synchronously. The spur gears '56, 57, 58, 59and 60 may all be angularly adjustable to provide a ready means forproperly timing the relative positions of the ribs, scoring elements andbars upon the cylinders 23, 27, 38 and 40 in their respectivecooperative rotations. Thisfeature is important particularly with regardto corrugating unit 22 inasmuch as the two cylinders 23 and 27 may be sorelatively adjusted that a suitable amount of clearance exists betweenthe ribs on the two cylinders and the bars 26. -In other words,clearance is provided between the co-acting ribs and bars so that thesides of the corrugations formed in the sheet 3' are not gauged or cut.

The bars 26 are fastened at each end to sprocket chains 61, the barsbein spaced a e propriatelyto mesh with the ri s u on t e uppercorrugating cylinder 23. he bar chain 25 is primarily driven by two.sprocket wheels (not shown) rigidly connected to the cylinder 23 andover which the chains 61 travel. The path of travel of the bar chain 25is substantially rhomboidal, and is guided at each of its corners by aseries of sprocket wheels. The sprocketwheels, as above mentioned, guidethe chain 61 at the upper acute angle of travel, two sprocket wheels 63guide the sameat the lower obtuse angle of travel,

two sprocket wheels 64 guide the same at the lower acute angle oftravel, and two sprocket wheels 65 guide the .same at the upper obtuseangle of travel. Hence, a continuous path is provided for-the bar chain25, the same being conducted by the sprocket clgain 61 over'the variouswheels described a ove.

wheels 63. The .cylinder 67.are bot To prevent the bar chain 25 frombreaking engagement with the corrugated sheet, when passing from thecorrugating unit 22 to the scoring unit 37 and from the scoring unit tothe joining unit, the sprocket chain 61 at each side of the bar chain 25is guided parallel to the platform 45 by means of tracks 45, which maybe positioned on each side of the platform 45 and parallel to thesurface thereof. By this means the bar chain 25 is positively held inengagement with the corrugated sheet while the same is traveling in aninclined plane.

The corrugated sheet 30 in registration withthe bar chain 25, afterassing from thescoring unit 37, changes its direction of travel andassumes a substantially horizontal path. Simultaneously upon changingdirection, the lower-portion of the corrugated sheet 30 is brought intocontact with theup per surface of the base sheet 18. Pressure ismaintained between the two strips 30 and 18 by means of the sprocketwheels 63, holding the bar chain 25 and sheet 30 in contact with thesheet 18, which in turn is held in contact with the sheet 30 by means ofavbelt 6.6 which passes over a cylinder67, positioned immediatelybeneath the axis of the sprocket rocket wheels 63 and adjustablerelative to each other, that is, their centers of rotation; I

may be brought tdward or away from eacl llf other. hand wheels 68 and 69for the wheels 63 and cylinder 67, re 'tively, and associated gear andscrew mei hi nism similar to that de scribed in connection with thepressure rolls The adjusting mechanism com 8 and 9, the corrugating unit22 and scoring" unit 37.

It can be readily observed that the corrugated strip 30 is fed to thepoint of juncture at an angle to the plane of the strip 18. This featureof the device eliminates the possibility of tearin or sliding thecorrugations u on the base s eet, since no relative motion 0 thecorrugated strip to the laminated board exists,-the travel of the belt66 and a a the chain 25 being synchronized. The syn-- chronizing meanscomprises a sprocket wheel (not shown) rigidly connected to the sprocketwheel 64, which drives a sprocket chain 70, as shown in Fig. 1a, whichin turn drives an idler sprocket wheel (not shown), and rigidlyconnected thereto is a spur gear 71- which meshes with another spur gear72 rigidly connected to a rear belt pulley 73. Thus the bar chain 25 andthe belt 66 are time and no relative motion of translation existsbetween the two. I do not wish to be limited to the specific means ofsynchronizing thetwo above described elements inasmuch as the inventioncontemplates the use of other suitable timing means.

After leaving the joining members 63 and 67, the composite board 74travels in regisyea tration with thebar chain 25 and the belt 66 to apunching or knock out roll 75. The belt 66 in its upper travelpreferably slides upon the plane surface of a table 76. Sufficientclearance is provided between the table top and the bar chain 25 toproduce a slight amount of compression upon the board 74 travellingtherebetween. The table is supported throughout its len h by a plural-7, the adjust-' ity of adjustable supports ment mechanism comprisingscrews 78 operated by handwheels 79. By this means the proximity of thesurface of the table 76 to the bar chain 25 can be regulated.

The knockout roll has disposed upon its surface studs or the like 80,which are adapted to contact the scored tabs 81 and completely severthem from the rectangular crests 46. By the same operation the tabs areforcibly applied and adhesively united to the base sheet 18 immediatelybelow the apertures in the crests formed by completely severing thescored tabs. The roll 75 is driven in timed relation with the remainingmechanism by means of a sprocket chain-82, which operatively connectsthe roll 75 to the remaining rolls in an obvious manner. After leavingthe knockout unit chain 25, belt 66 and board 74 held therebetweentravel horizontally along the top of the table. The bar chain 25 may beheld in contact with the upper surface of the board 74 by means ofguides 83, in which the sprocket chains 61 are adapted to travel. Hence,by adjusting the table upwardly or downwardly a desired amount ofpressure may be brought -to bear upon the board 74.

If it is desired to apply greater pressure to the bar chain a set. ofpressure bars 84 may be provided. The bars may be adjustable by means ofa hand wheel 85 to which is rigidly fixed a bevel gear 86 which mesheswith another bevel gear 87 rigidly attached to a screw 88. The screw 88upon being rotated is adapted to raise or lower a bearing block 89slidably positioned in uides90. A rod 91 is journalled in the locks 89on each side of the machine and is adapted to be raised and lowered withthe blocks 89. Mounted upon the rod 91 adjacent each end thereof is oneof the pressure bars 84. The bars 84 upon being lowered rest upon thetop of the bar chain 25, as shown best in Fig. 6, and press the bars 26of the bar chain tightly upon the board 74.

Upon travelling a suitable distance along the table 76 to permit theproper setting of the corrugated sheet 30 upon the laminated board 18,the bar chain 25'breaks contact with the board 74, and doubles back overthe wheels 64. The board continues to travel along the table 76 and uponleaving the same may, if desired, pass over a rotary brush 92 journalledat 93 in a receptacle 94. The receptacle 94 is adapted to contain anon-adhesive substance such as talc or the like, and by means of thebrush 92 a coating of the same is de osited upon the lower surface ofthe board 4.

The board then leaves the machine proper and passes to a conveyor (notshown) upon which it is conveyed a predetermined distance to allow' theadhesive to cool sufficiently to permit cutting of the board if suchoperation is desired.

It is to be noted that the machine is desifgned to corrugate while acontinuous strip 0 fibrous material to be corrugated is beingcontinuously fed at an angle to the horizontal. I have discovered thatit is preferable in some cases to corru ate a continuously advancingsheet of brous material while it is travelling at an angle to thehorizontal rather than to corrugate the same sheet while it is advancingin a horizontal plane.

The reason for this is that it is ex edient, when using a base sheetbuilt up 0 a plurality of plies of individual sheets, to maintain thepath of travelof the base sheet in a' straight line, inasmuch as thebase sheet is generally stifier and thicker than the corrugated sheet,and, therefore, difiicult to bend. Hence, it is advisable to change thedirection of travel of the corrugated sheet to conform with that of thebase sheet rather than vice versa, and inasmuch as the base sheet is tomove in a straight line, it is preferablethat this line be in ahorizontal plane. Of course it is to be understood that this is not tobe taken as a limitation of the invention, since various relativedirections of feed may be utilized.

As pointed out in the objects of the invention, the machine essentiallycomprises means for feeding two separate strips of fibrous material,corrugating and scoring means acting on one sheet, means for uniting thecorrugated and scored sheet with the second uncorrugated sheet, meansfor completely severing the scored portions and uniting the cut-outsthus produced to the base sheet immediately ad acent the apertures thusproduced, and means for prevent ing collapse of the corrugations andmaintaining the two sheets in contact until the adhesive has setsufficiently to prevent spreading or creeping.

I claim as my invention:

1. A machine comprising in combination means for uniting a continuouslyadvancing corrugated sheet with a continuously advancing uncorrugatedsheet, means acting on the corrugated sideof said united strum beingunited to prevent creeping of one sheet relative to the other.

2. A machine comprisin in combination, means for feeding a plura 'ty ofadvancing strips of fibrous material, means for corrugatmg one advancingstrip, means for scormg portions of said corrugated. sheet atspacedintervals, means for adhesively unitmg said corrugated sheet witha continuo ously advancing uncorru ated sheet, means for completelysevering t e scored portions of the corrugated sheet and uniting thecutouts thus produced to the corrugated sheet, and means for maintainingthe corrugated and uncorrugated sheet in until the adhesive has set suciently to prevent creepin between the two sheets.

3. A machine comprising in combination, means for feeding a continuousstrip of go fibrous material at an angle to the horizontal, means forcorrugating said sheet while travelling in said plane, means for scoringsaid advancing strip at spaced intervals, means for feeding a secondstrip of fibrous material in a horizontal plane, means for applyingadhesive to one of the opposed surfaces of the two continuouslyadvancing strips, means for uniting said continuously advancing stripsthrough the medium of said adhesive, means for carrying said unitedstructure in a horizontal plane, means for completely severing thescored portions of the-corrugated strip and positively uniting thecut-outs thus produced with the base sheet, and means for maintainingpositive contact between the corrugated and uncorrugated strips untilthe adhesive has set su ciently to prevent creeping.

4. A machine for manufacturing plaster board comprising in combination,corrugating rolls for forming alternate ribs and depressions in acontinuously advancing sheet,

scoring rolls for scoring said ribs at spaced intervals, pressure rollsfor adhesively uniting the corrugated sheet to the laminated board,knockout means, comprising a cylinder, thesurface of which is providedwith a plurality of spaced studs, for severing said scored .portions andpositively uniting the cut-outs thus formed to the laminated board. 5.A-machine for manufacturing plaster board comprising in combination,corrugating rolls for forming alternate ribs and depressions in acontinuously advancing sheet, scoring rolls for scoring said ribs atspaced intervals, pressure rolls for uniting a plurality of continuouslyadvancing sheets to form a laminated board, a second set of. pressurerolls for adhesively uniting the corrugated sheet to the laminatedboard, knockout means, comprisin a cylinder, the surface of which isrovide with a plurality of aced studs, or severing said scored portlonsand positively uniting the cut-outs 05 thus formed to the laminatedboard.

ositive contact pressure rolls for adhesively uniting the corrugatedsheet to the laminated board, knockout means, comprising a cylinder, thesurface of which is provided with a plurality of spaced studs, forsevering said scored portions and positively uniting! the cut-outs thusformed to the laminated board, and means comprising a continuous chainof transversely extending bars insertable between the rigs of thecorrugated sheet in consecutive order to prevent flattening of thecorrugations.

7. A machine for manufacturing plaster board comprising in combination,corrugating rolls for forming alternate ribs and depressions in acontinuously advancing sheet, scoring rolls for scoringsaid ribs atspaced intervals, pressure rolls for uniting a plurality of continuouslyadvancing sheets to form a laminated board, a second set of pressurerolls for adhesively uniting the corrugated sheet to the laminatedboard, knockout means, comprising a cylinder, the surface of which isprovided with a plurality of spaced studs, for severing said scoredportions and positively uniting the cut-outs thus formed to thelaminated board, means comprising a continuous chain of transverselyextending bars insertable between the ribs of the corrugated sheet inconsecu tive order to prevent flattening of the corrugations, and meansfor maintaining pressure on-the corrugated sheet and laminated boardafter being united to prevent them from separating.

8. A machine comprising in combination, a corrugating unit comprising apan of co-acting cylinders, the surface of one of which, is providedwith spaced longitudinal ribs, and the surface of the other of whlch isprovided with a plurality 'of alternate spaced ribs and spaced beads, anendless chain comprising spaced transverse bars providedv withlongitudinal grooves adapted to be insertable between the ribs of thefirst mentioned cylinder, said grooves and the beads of the secondcylinder being in register, and means for passing the material to becorrugated continuously between the two cylinde I In testimony whereof Iaflix my signature HARRY A. CUMFER.

